sulzer aixfotectm twin screw extrusion advanced foam

Sulzer aixfotecTM Twin Screw ExtrusionAdvanced Foam Technology

Applications

Advanced Extrusion SystemsThermoplastic Foam Applications

Sulzer aixfotecTM manufactures specialized extrusion lines for polymer foam productions.Development and manufacturing of production lines for the foam industry are our core competencies.Sulzer aixfotecTM industry solutions reflect 30 years of development work in the foam industry.

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XPS Foam Profile Extrusion

From decorative products to pipeline insulation extruded polystyrene foam profiles find their applications in diverse fields. Customized die technology allows nearly any modification in product design.Sulzer aixfotecTM holds all technical and process know how necessary for fast production start-ups reducing time to market to a minimum.Sulzer aixfotecTM and their OEM suppliers are working under German VDMA standards.Sulzer aixfotecTM offers a unique set of customer and product specific XPS foam profile production lines for a variety of applications from pilot lines to high volume production systems.

XPS Foam Profile Extrusion

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TS 060 L/D 24Melt Cooler Typ 660

Homogenizer Typ 75-2DTwin Die

Technology

Advanced Extrusion SystemsXPS Foam Profiles

XPS direct gas twin screw extruders are designed according to industry requirements: process stability, reliability and product quality. XPS extrusion lines provide a wide range of densities (60 kg/m³-300 kg/m³) and output rates.

Twin screw extruder

Advanced twin screw extruder char-acterized by high efficiency mix-ing combined with low energy con-sumption per kg output. High torque screws designed specifically for

foam applications. Data visualization of all machine parameters and set-points. Customized data-log, data-trend and data-archiving. Start/stop security loop involving gravimetric

dosing unit, gas metering/dosing, melt pressure and melt temperature. State of the art melt temperature control based on steering algorithm developed for XPS foam extrusion.

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Gas metering and dosing unit:

Metering and pumping systems for pentane, propane, butane, N2 or CO2 are available. Gas pump station and metering system are designed to allow large variability in output. Direct gazing technology for lower production costs.From plant layout, to infrastructure work a full package is provided to our customers!

Die technology

Sulzer aixfotecTM die technology empowers market leaders to reach cutting edge quality, lower density levels and high output. Single die and twin die technology are proven standards.Niche market applications or opti-mization of your mass production?We have the right answer!

XPS Profile Calibration

The calibration is installed in the water cooling trough to optimize shaping and for constant profile size.The better the equipment the high-er your return!

Puller and numerical flying saw unit

Puller with long soft PU bands lim-iting profile deformation com-bined with a numerical 2 axis flying cut-ting saw designed for perfect angu-lar cuts at any speed.Profile length in narrow tolerances without brews ready for packaging!

In-line dryer

Combined succion technology and hot air blowers give an effective drying system.In-line printing or in-line painting is leading to quality improvements and cost reduction!

Gas metering and dosing unit Puller and numerical flying saw unit

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Technical DataXPS Profile Extrusion

Technical Data

Extruder typ Screw Process Max Max Melt cooler Foam outputdiameter length screw drive

speed power[mm] L/D [rpm] [kW] [mm] [kg/hr]*

TS 060 60 24 120 47 660 - 860 30 - 120TS 075 75 24 120 90 860 40 - 150TS 090 90 24 120 154 1260 60 - 250

*depending on density, polymer and blowing agent

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XPS, XPE, XPP, XPET Foam Sheet Extrusion

Foam sheet extrusion

XPS, XPE and XPP are the most popular foam sheet applications. XPET foam sheets are an emerg-ing application with high potential. Mass markets are found in the following sectors: food, construc-tion, packaging, furniture, bedding and automotive industries. Sulzer aixfotecTM holds all technical and process know how necessary for

fast production start-ups reducing time to market to a minimum. Sulzer aixfotecTM and their OEM suppliers are working under German VDMA standards. Sulzer aixfotecTM offers a unique set of customer and prod-uct specific foam sheet production lines for a variety of applications, from pilotlines to high volume pro-duction systems.

XPS, XPE, XPP, XPET foam sheet extrusion

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Advanced Extrusion SystemsXPS, XPE, XPP, XPET Foam Sheets

XPS, XPE, XPP and XPET foam sheets can be processed on Sulzer aixfotecTM extrusion lines in a wide range of densities and output rates.

Twin screw extruder

Sulzer aixfotecTM twin screw extruder are characterized by high efficiency mixing combined with low energy consumption per kg output. High torque screws designed specifically for foam applications. Data

visualization of all machine pa-rameters and setpoints. Custo- mized data-log, data-trend and data-archiving. Star t and stop security loop involving gravimetric dosing unit, gas metering and

dosing, melt pressure and melt tem-perature. State of the art melt tem-perature control based on steering algorithm developed specifically for the extrusion of foam sheets.

TS090 L/D 24Melt Cooler Typ 1260Homogenizer 140-2D

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Adjustable cooling can mandrel

Build on moving trolley to allow fine adjustments in distance to the die. Cooling can easy to adjust for changes in sheets width. Integrated blower system.

Adjustable cooling can mandrel S-wrap puller

Melt cooler and homogenizer

A perfect melt temperature is key for high quality in foam production. Melt cooler and homogenizer systems are designed for homogeneous melt streams and process management at any throughput rate. The com-bined homogenizer and melt cooler units are equipped with oil heating and cooling units. The controller is programmed with cooling algorithm eliminating the risk of undershoot-ing the set point temperature. Lower scarp rate and faster start-ups are the proven benefits of our system!

S-wrap puller

With cooled rolls (XPP) or rubber rolls (XPE). Flattening roll to avoid side displacement. High security level.

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TS 060 60 24 120 47 660 - 860 30 - 120TS 075 75 24 120 90 860 40 - 150TS 090 90 24 120 154 1260 60 - 250TS 120 120 24 120 280 2 x 1260 90 - 500TS 150 150 24 120 418 2 x 1260 90 - 900


Technical DataXPS, XPE, XPP, XPET Foam Sheet Extrusion

Technical Data

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XPE, XPP Foam Pipes and Profiles

Die technology: single, twin, fourfold or eigthfold die outlets

Die changer

The die changer enables quick changes of die profile shape in run-ning production. Lower downtime and simple handling reduces scrap rate and daily complexity in pro-duction.

Die technology

Sulzer aixfotecTM die technology em-powers market leaders to reach cut-ting edge quality, lower density le-vels and high output. Single, twin or multiple die technology are proven standards. Niche market applica-tions or optimization of your mass production?We have the right answer!

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Advanced Extrusion SystemsXPE, XPP Foam pipes and profiles

Profiles and pipe insulation are produced in XPE or XPP. Mass markets are found in the following sectors: construction, packaging, furniture, bedding and automotive industries.

Technology

Twin screw extruder

Sulzer aixfotecTM twin screw extruder are characterized by high efficiency mixing combined with low energy consumption per kg output. High torque screws designed specifical-ly for foam applications. Data visu-alization of all machine parameters and setpoints. Customized data-log, data-trend and data-archiving. Start and stop security loop involv-ing gravimetric dosing unit, gas me-tering and dosing, melt pressure and melt temperature. State of the art melt temperature control based on

steering algorithm developed pecifi-cally for the extrusion of XPE foam profiles and pipe insulation. Sulzer aixfotecTM XPE extrusion systems offer many expansion options (e.g. multi-co-extrusion). Years of ex-perience in development of a vari-ety of proven industrial plant types, tool designs and process technolo-gies reduce implementation risks to a minimum. Our team can support you in developing the industrial solu-tion and process design required by your product concept. Sulzer aixfo-

tecTM holds all technical and process know how necessary for fast produc-tion start-ups reducing time to mar-ket to a minimum. Sulzer aixfotecTM and their OEM suppliers are work-ing under German VDMA standards. Sulzer aixfotecTM offers a unique set of customer and product specific foam pipe and profile extrusion lines for a variety of applications, from pi-lot lines to high volume production systems.

TS 075 L/D 24Melt Cooler Typ 1260Homogenizer 140-2D

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CO-Extrusion

Co-extrusion systems are increa-singly used for a number of technical applications enhancing foam perfor-mance or coloring. Inline foam skin-ning improves product properties and value added. Skinning on pipe insulation to alemiorate UV stabil-ity or mechanical properties is only one of a large variety of applications.

Co-extruded foam skinning technology Puller and hacksaw unit for XPE foam profiles

Puller and Hacksaw unit

High speed puller with integrated hacksaw. Build in pre slitting unit for pipe insulation. Twin puller bands designed for more than one cut per second. Pipe and profile length in narrow tolerances ready for pack-aging!

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TS 060 60 24 120 47 660 - 860 30 - 120TS 075 75 24 120 90 860 40 - 150TS 090 90 24 120 154 1260 60 - 250TS 120 120 24 120 280 2 x 1260 90 - 500TS 150 150 24 120 418 2 x 1260 90 - 900


Extruder typ Screw Process Max Max Outputdiameter length screw drive

speed power[mm] L/D [rpm] [kW] [kg/hr]

SS 045 45 30 450 25 10 - 100

Technical DataXPE, XPP, Foam Pipes and Profiles Extrusion

Technical Data

Co-Extrusion Skinning

Foam Extruder

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Extrusion of direct gazed ex-pendable or expanded beads

One of Sulzer aixfotecTM core com-petences is the development of ex-trusion lines for EPS producers. The production of direct gazed expand-able polystyrol granules (EPS) by extrusion based processes is world-wide on advance. In comparison to large scale productions based on suspension-technology this process is characterized by its high efficiency

EPS, EPE, EPP, EPET Beads Extrusion

EPS, EPE, EPP, EPET beads extrusion micro pelletizing

in the production of special applica-tions. The extrusion systems reach outstanding quality levels and allow efficient production of low volume se-ries or specialised products. Sulzer aixfotecTM holds all technical and pro-cess know how necessary for fast production start-ups reducing time to market to a minimum.

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Advanced Extrusion SystemsExpandable and Expanded Beads

Innovative processes as i.e. EPS, EPE, EPP and EPET beads produced by direct gazed extrusion require optimized processing technology.

Technology

Direct gassing twin screw extruder

Advanced twin screw extruder char-acterized by high efficiency mix-ing combined with low energy con-sumption per kg output. High torque screws. Customized engineering based on process and application properties. Data visualization of all machine parameters and set-points. Customized data-log, data-trend and

data-archiving. Start and stop secu-rity loop involving gravimetric dos-ing unit, gas metering and dosing, melt pressure and melt tempera-ture. State of the art melt tempera-ture control. Designed for small and medium prodution size. Efficient pro-duction of special products. Easy shift between products: lower energy

consumption, reduced maintenance, less space, superior quality, variabil-ity on output, can be customized to your needs! The cutting chamber of the under water pelletizer is com-pletely filled with process water. The pelletizer cuts polymer strands into pellets immediately after they have passed the die plate.

TS 075 L/D 24Melt Cooler Typ 650Under Water Granulating System Spin Dryer

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Centrifugal pellet dryer

The centrifugal pellet dryer sepa-rates process water and pellets. Pellets move helically upwards to the top of the dryer and are leaving the dryer continuously through the pellet outlet. Because of the rebound effect and the counter current airflow generated by the exhaust blower the pellet outlet moisture is designed for less than 0.05% depending on the type of polymer and hygroscopy.

Full metal granulating head and knifes

Granulating head and knifes de-signed for long lifecycles. Coating by melted carbide reduces main-tenance costs to a minimum. In-creased life span and lower wearout. Holes are fabricated by wire erosion for better surface quality. Holes as small as diameter 0,45 mm.Granulating heads oil heated for high quality round shaped beads in a nar-row distribution.

Gas metering and dosing unit and CO2, Pentane, Butane, Propane...

Under Water Pelletizer and drying sytem

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TS 075 75 24 - 52 120 - 450 90 560 - 860 200 - 450TS 120 120 24 - 52 120 - 450 280 860 - 1260 up to 1500TS 140 140 24 - 52 120 - 450 846 1260 up to 3000

*depending on polymer, blowing agent, additives and bead sizes

Technical DataEPS, EPP Micro Pellets and Beads ExtrusionE... polymer of your choice

Technical Data

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Laboratory Extrusion Systems

Sulzer aixfotecTM laboratory extru-sion lines are widely used to develop foam ability on various polymers, various gases and various foam applications.

Laboratory Extrusion SystemsLaboratory Extrusion Systems

Laboratory Extrusion Systems

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Advanced Extrusion SystemsLaboratory Extrusion

The laboratory foam line has the same processing characteristics as the industrial line.This facilitates upscaling of any process.

Technology

The extruder is defined as a co-rotating, intermeshing twin screw with direct gassing option by usage of physical blowing agents. Depend-ing on the targeted processes the processing equipment can be build to run temperatures up to 400°C. As an option the system can be designed to process various gases.

Injection of one or more gasses or a cocktails of gasses is possible. Feeding of powders through side feeder and various different down-stream equipment are available depending on the process. Under water pelletizer and dryer systems for expandable or expanded beads (EPS, EPP, E…).

TS 030 L/D 40Melt Cooler Typ 360Under Water Granulating Gravimetric FeederMultiplGas Dosing and Meetring System

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For a deeper analysis of the raw material mix a second set of screws to realize lab size master batches can be provided. For foam sheets and profiles an adapter to the die and necessary die technologies with cooling section and puller en-able simulations of real production characteristics on laboratory scale.

Foam extruder TS 030 with melt cooler typ 360 in laboratory size

Output range from 3 kg/hr up to maximum of 30 kg/hr. The laboratory foam line has the same processing characteristics as the industrial line. Therefore the twin screw extruder the relation of min. to max. output is generally a multiple of 10x. This facilitates upscaling of any process.

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TS 020 20 24 - 52 600 7.5 360 1 - 10TS 030 30 24 - 52 600 13 360 3 - 30TS 045 45 24 - 52 600 18 360 6 - 60

*output is related to the research field, typ of polymer and blowing agent.

Sulzer aixfotecTM laboratory lines are designed for working temperatures up to 420 °C.Foam extruders can be equiped with side feeders for powder additives.

Sulzer aixfotecTM provides the ability to equip laboratory extruders with two screw sets: foam and masterbatch.



TS 060 60 24 - 52 120 - 600 47 560 250TS 075 75 24 - 52 120 - 600 90 660 450

*output is related to the research field, typ of polymer and blowing agent.

Technical DataLaboratory Foam Extrusion

Technical Data

Laboratory Foam Extruder

Semi Industrial Foam Extruder

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XPET board extruder screws are designed to reduce shear heat and allow to process regrind material. XPET melt cooler systems are de-signed in modules with seperate oil heating and cooling units. Oil tem-pered strand dies ameliorate melt temperature steering and tempera-

XPET Board Extrusion

XPET board extrusion

ture gradient between extruder end and die exit. XPET calibrators and post calibrator units lead to an op-timized product finish. Gas stations build to process gas coctails are key developments to reach lower densi-ties and improve product quality.

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Advanced Extrusion SystemsXPET Foam Boards

XPET board extruders are designed to minimize shear heat and to allow processing of PET regrind material.

Twin screw extruder

Advanced twin screw extruder char-acterized by high efficiency mixing combined with low energy consump-tion per kg output. High torque screws designed specifically for foam ap-plications. Data visualization of all machine parameters and set-points. Customized data-log, data-trend and

Technology

data-archiving. Start/stop security loop involving gravimetric dosing unit, gas metering/dosing, melt pressure and melt temperature. State of the art melt temperature control based on steering algorithm developed for XPET foam board extrusion.

TS 140 L/D 24Twin Melt Cooler Typ 1260Homogenizer Typ 175-2D

Plank Die with Strand Die Plate

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Modular melt cooler for XPET board extrusion

Controlling and steering melt tem-perature is key for high quality in XPET foam board production. Mod-ular melt cooler systems split the cooling process in several cooling zones. High volume XPET extrusion systems require temperature control at any throughput rate. The combi-nation of several melt cooler zones each equipped with oil heating and cooling units leads to high precision in temperature steering. Each con-troller is programmed with cooling algorithm eliminating the risk of undershooting the set point tem-perature.

Down Stream Equipment

Down stream equipment with inte-grated cutting, milling and cooling units. I.e.: plank cooling on pater-noster systems if available floor space is an issue.

Gas station for multiple gas coctails XPET board extrusion

Please contact us for extruder sizes and output ratios.Sulzer aixfotecTM services include layout of complete lines, P&ID, detailed infrastructure engineering.

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Central Operating SystemOptimal operation with the right control system

Central operating system to meet specific requirements.

Philosophy

Central operation at one point, almost independent from the complexity of the automated production line. With the integration of all aggregates in

Control System

one operating system additional operating terminals are no longer necessary. Consequently errors are minimized.

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Using a central panel the operator has quick access to all line compo-nents, parameters and process fac-tors. The reaction to processing situ-ations is essentially accelerated and the workflow is optimized. The central operating system was developed for the operator‘s demands. This results in easy handling of the complete sys-tem along the process chain leading to transparency in the workflow and high availability of the lines.

Production Analysis System

Philosophy: Reproducability of pro-cesses and documentation of pro-cessing parameters become more and more important. Continuous analysis and supervision improve control on production processes.

The production analysis system can file the following data types: analogue values (i.e. temperatures, pressures), binary values (events, alarms).

Analysis Tools: Online and historic trend, online and alarm histo-ry, production events, reports like shift protocols, parameter values… Batch related recording, statistics, storing of any configuration.

Processes will be filed in a stan-dardised data base.

Smooth communication with other systems can be guaranteed. Open interfaces facilitate integration in the IT structure. Options available to con-nect to existing MES/ERP systems.

Service Center

Build in modem with 24 hours help desk is a Sulzer aixfotecTM service that reduces down time and production losses to a minimum.

Central Operating System

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Legal Notice: The information contained in this publication is believed to be accurate and reliable, but is not to be construed as implying any warranty or guarantee of performance. Sulzer Chemtech waives any liability and indemnity for effects resulting from its application.

The activity program comprises:• Process components such as fractionation trays, structured and ran-

dom packings, liquid and gas distributors, gas-liquid separators, and internals for separation columns

• Engineering services for separation and reaction technology such as conceptual process design, feasibilities studies, plant optimizations in-cluding process validation in the test center

• Recovery of virtually any solvents used by the pharmaceutical and chemical industry, or difficult separations requiring the combination of special technologies, such as thin film/short-path evaporation, distilla-tion under high vacuum, liquid-liquid extraction, membrane technology or crystallization.

• Complete separation process plants, in particular modular plants (skids)

• Advanced polymerization technology for the production of PLA and EPS

• Tower field services performing tray and packing installation, tower maintenance, welding, and plant turnaround projects

• Mixing and reaction technology with static mixers• Cartridge-based metering, mixing and dispensing systems, and dis-

posable mixers for reactive multi-component material

Sulzer Chemtech Ltd, a member of the Sulzer Corporation, with headquar-ters in Winterthur, Switzerland, is active in the field of process engineering and employs some 4000 persons worldwide.Sulzer Chemtech is represented in all important industrial countries and sets standards in the field of mass transfer and static mixing with its ad-vanced and economical solutions.

www.sulzer.com Please check for your local contact

sulzer aixfotectm twin screw extrusion advanced foam

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